Method of multiarc welding



' March 16, 1948. c. w. s'rEwARn AL 2,437,340

METHOD OF MULTIARC WELDING Filed larch 9, n44 2 Sheets-Sheet 1 mmvron. Y coLaY wesrou s'rzwmn By uALcoLu R. mvauauneu A TTOR'NE Y March 16, 1948.

C. W. STEWARD El AL METHOD OF MULTIARC WELDING Filed March 9, 1944 2 Sheets-Sheet? FIG. 5

INVENTOR. COLBY WESTON STEWARD MALCOLM R. RIVENBURGH ATTORNEY Patented Mar. 16, 1948 UNITED STATES PATENT OFFICE METHOD OF MULTIARC WELDING Colby Weston Steward, Kenmore, and Malcolm R. Rivenburgh, Williamsville, N. Y., assignors, by mesne assignments, to Cornell Research Foundation, Inc., a corporation of New York Application March 9, 1944, Serial No. 525,740 (01. 219-10) 8 Claims. 1

The present invention relates to arc welding. More specifically, it relates to the arc welding of thin metals, and is particularly suited for aluminum and its alloys.

The fusion welding of very thin sheet metal is difiicult, and in the case of light alloys hitherto has been practically impossible. It is generally considered impractical to are weld a butt joint in aluminum or aluminum alloy sheet, when the thickness is less than A; inch. When a sheet of this order of thickness is composed of 24S aluminum alloy, it has been almost impossible to make, by existing methods, a fusion weld which would not crack as fast as it was welded.

It is therefore an object of this invention to provide a method which can be employed to fusion weld aluminum and aluminum-base alloys as thin as (0.016) inch without cracking. It is another object to provide such a method which can be employed to butt weld aluminum and aluminum-base alloy sheets so as to develop from 75 to 100 per cent of the full strength of the sheet metal in a tension test. Other objects will appear hereinafter. The apparatus associated with this method is covered by a divisional application, Serial No. 738,098, filed March 29, 1947.

These objects are accomplished, according to the present invention, by providing an arc welding method wherein two or more arcs are operative at the same time during the fusion period, and in which one of the arcs is struck between the Work piece and an electrode, preferably a flux-coated or similar consumable metallic electrode, preferably with a direct current source, and another are is struck with a carbon electrode as at least one of its electrodes, preferably with an alternating current source.

In the drawings: Figure 1 is a general schematic View of a preferred arrangement for practicing the present invention. Figure 2 is a schematic view of a salt solution which may be substituted for the resistance network operating as a resistance medium in the arrangement of Figure 1. Figure 3 is a general schematic view of another arrangement for practicing the invention in which two independent electric circuits are provided to secure two arcs. Figure 4 is a general schematic view of still another arrangement for practicing the invention, in which the two electric circuits are connected through one of the carbon electrodes. Figure 5 is a general schematic view of still another arrangement for practicing the invention, in which the two electric circuits are connected through the work piece.

One of the arcs, in accordance with the preferred embodiment of this invention, is struck between two similar carbon electrodes, and may be termed a twin carbon arc, or a twin carbon torch. Conveniently, it may be produced by means of a pair of carbon rods held at an angle to each other. In practice, it has been found that ordinary commercial carbon welding rodsapproximately 6 or 8 inches long and A; to inch in diameter may be used, held at an angle of approximately 10 to 15 or more to each other. The heat produced by the twin carbons may be varied by regulating the arc gap and also by moving the torch near to or away from the work. The twin carbon arc or twin carbon torch may be supplied with current from any suitable source, such as a commercial alternating current welding machine. Best results are obtained when alternating current is used for the twin carbon torch, although direct current may also be used. Alternating current has the advantages that equal burn-oii of the carbons is provided and that symmetrical arcing from the carbons to the work piece occurs, which would not be the case for direct current.

The use of the twin carbon torch has a number of advantages and functions. Firstly, it serves to preheat the sheet at the starting point of welding. Secondly, the degree of heat can be controlled, as described above. Thirdly, the presence of the arc acts as a partially shielded atmosphere. Fourthly, when used in combination with a metallic are as hereinafter described, it assists in supporting the metallic arc, because the current used in the metallic arc circuit is, in this process, too low to be maintained independently of the carbon torch. Fifthly, it helps to melt the metal and flux of the filler rod. These functions and advantages assist in securing perfect fusion while welding aluminum and aluminum alloys.

A second arc, in accordance with the preferred embodiment of this invention, is struck between the work piece and any suitable metallic electrode, preferably flux-coated, although bare electrodes may also be used. For this circuit, direct current is preferably used, and any suitable source, such as a commercial direct current welding machine, may be employed for this purpose. The polarity for the metallic arc may be either straight or reversed, depending upon the material to be welded and the rod used. Reverse polarity (i. e., with the work-piece the negative terminal) is preferably used with thin sheets, particularly while welding aluminum and aluminum alloys. Accurate control of the current for the metallic arc is obtained by the use of a rheostat. The metallic arc may be continuous or intermittent as desired, depending upon the manipulation of the rod.

With the use of a twin carbon arc and a meta1- lic arc, as described above, it is preferred to interconnect the sources of current for these two arcs by means of a resistance network or analogous means. With this arrangement, a number of additional arcs are formed which greatly assist observed through the medium of high-speed? One of these additional arcsphotography. passes from one carbon electrode to the work piece, another from the second'carbon electrode to the work piece, and a third from one oithe carbon electrodes to the metallic electrode. A total of five arcs is thus secured with this ar- ,rangement.

In-the preferred form of the invention, a twin carbon arc is used at the start to preheat the work piece, or the metallic rod, or both. During thisperiod, the arc is playing between the carbon electrodes. The metallic electrode and the twin carbon electrodes are then brought closer to each other, and finally the metallic electrode is brought so as to be almost touching the plate. The arcs thenpass between the flux-coated electrode, the carbon electrodes, and the work, thereby producing the necessary welding heat by means of a multiplicity of arcs.

Referring now to Figure l of the drawings, a flux coated metallic electrode H is connected 7 through terminals l3 and 14 and resistance element 23 of a resistance network |2 to the positive terminal of a direct current welding machine ll, supplying direct current at 50'to 100 volts. The negative terminal of the welding machine i? is directly connected to the work piece It. Two carbon electrodes 2| and 22 constitute a twin carbon torch, and are connected to an alternating current welding machine 20, supplying alternating current at 50 to 100' volts. Electrode 2% is connected directly, while electrode 22 is connected through terminals l5 and H5 and resistance elem'entZt of'resistance network I2; Interconnection between the alternating current circuit and the direct current circuit is obtained through resistance elements 24, 25, 21 and 28 in resistance network |2 and forming connections between resistances 23 and 26.' The resistances 23, 24, 25,

26,21 and 23 may have any convenient quanti tative value necessary to secure the proper control of the welding operation and the arcs formed therein.

In operation, anarc is first struck between elec-- trodes 2| and 22. The metallic electrode H is then brought'close to the work piece l8, after which the twin carbon torch is brought adjacent toboth the metallic electrode H and the work piece 8. When the proper degree of pre-heat has been attained,the second arc, between the fluxcoated electrode H and the work piece |8,is struck, and the welding operation completed by 7 working the electrodes along the joint to be welded, as shown in Figure 1. During this operation, multiple arcs willbe evolved, i. e., from the metallic electrode II to the work piece I8 and to one of the carbon electrodes 2| and 22, from the work piece l8 to-each of the carbon electrodes 2| and: 22, and from the carbonelectrodes 2| and 22 to each other. This arrangement will secure a confined, easily controlled heating effect necessary for joining aluminum and aluminum alloys by fusion welding.

It is obvious that the arrangement of the cir-- cuits is not limited to that shown in Figure 1. For example, one terminal of the alternating current source may be connected'to the work 4 piece as well as to one of the carbons, producing a variable two-way action of the carbon are between the carbons or from either of the carbons to the work piece, depending upon the distance of the carbon from the work piece. An arc may also be drawn from one of the carbons to the metallic electrode or any combination of the above. It is: obvious that, with two electrical circuits, three electrodes and the work piece, there are numerous possible combinations.

Salt solutions, chokes or other equivalent devices, suitably arranged to produce the same stabilizing effect and fine adjustment of current as theresistance network l2, may be substituted for such resistance network. A vessel 32 containing a saline solution, for this purpose, is shown in'Figure 2 of the drawings, wherein the copper plates 33, 34, 35 and 36-are hung in the solution and connected to the various elements shown in-Figure 1, in place of terminals|3,' Hi, 5 and |6, respectively, of the resistance network l2. In: addition, it isobvious that a self-contained power unit may be utilized, comprising a suitable alternating-current transformer and a copper-oxide, electronic, electrolytic, or other equivalent rectifier "with resistors, chokes and reactors necessary to give good stability and fine adjustment of current.

Referring now'to Figure 3, this illustrates a form of the invention in whichthe two electrical circuits are electrically independent The electrode 4| is connected directly to the positive terminal of the direct current welding machine 42, while the work piece'd3' is connected directly to the negative terminal of the welding machine 42. The two carbon electrodes 44 and 45 are similarly directly connected to the alternating current welding machine 46. In this form, there is considerably less control of the various arcs than in the form shown in Figure 1. However, the are between electrodes and 45 does assist in supporting the are between electrode M and work piece 43. The operation is similar to that of the form shown in Figure 1.'

In Figure 4 is shown a form of the invention in which both direct current welding machine 52 and alternating current welding machine 58 are connected to one of the'carbonelectrodes 5 6. The other (negative) terminal of the welding machine 52 is connected to the work-piece 53, while the flux-coated filler rod 5| is not electrically connected. The second carbon electrode 55, connected to the welding machine 56, is shorter than the electrode 54, so that onearc is struck between the end of electrode "and the side of electrode 54, and the other are between electrode 54 and work piece 53. In operation, an 'arc is first drawn between the two carbon electrodes '54 and 55. This preheats the long carbon 54. Then the latter is touched to the work piece 53. so as to draw an are there. From the two arcs, sufiicientheat is developed to bring the surface of the work piece 53' and the filler rod 5| up to welding temperature.

ln the form shown in Figure 5, the two electrical circuits are connected through the work piece 63,- In this form only a single carbon electrode 54 is employed, connected to one terminal of the alternating'current welding machine .65. The opposite terminal of the welding machine 66 and the negative terminal of direct current welding machine 62 are both connected to the work piece 63. The positive terminal of welding machine 62 is'connected to a flux-coated or bare metallic rod 6|. In 'operatioman arc isfirst struck between electrode 64 and the work piece 63, in order to preheat the work piece. The metallic electrode 6| is then introduced so as to be almost touching the work piece 53, shifting the arc to pass between the carbon electrode 64, the metallic electrode 6! and the work piece 63, each arc supplementing the others.

In addition to the advantages previously mentioned, surface cleaning is not generally necessary while welding according to the present invention.

The above discussion has been in connection with several specific forms of the invention. It is obvious, however, that many changes may be made in these forms without departing from the spirit of the invention. It is to be understood, therefore, that the invention is not to be limited except as defined in the appended claims.

We claim:

1. A method of arc welding, comprising preheating an electrically conductive work piece and a metallic welding rod by means of a first electric are placed adjacent to said work piece and said welding rod until fusion has commenced, thereafter striking a second electric are between the welding rod and the work piece in the atmosphere of said first arc, and cooperatively moving said arcs along said work piece whereby to accomplish welding of said work piece, said first electric are being actuated by a source of alternating current and said second electric arc being actuated by a source of direct current.

2. A method of arc welding, comprising preheating an electrically conductive work piece and a metallic welding rod by means of a first electric arc placed adjacent to said work piece and said welding rod until fusion has commenced, thereafter striking a second electric are between the welding rod and the work piece in the atmosphere of said first arc, and cooperatively moving said arcs along said work piece whereby to accomplish welding of said work piece, said first electric are being actuated by a source of alternating current and said second electric arc being actuated by a source of direct current, and said two sources of current being interconnected electrically through one terminal of each of said sources.

3. A method of arc welding work pieces of thin sheet metals and alloys, comprising preheating the work piece and a metallic welding rod by means of a first electric are placed adjacent to said work piece and said welding rod until fusion has commenced, thereafter striking a second electric arc between the welding rod and the work piece in the atmosphere of said first arc, and cooperatively moving said arcs along said work piece, said two electric arcs having separate but interconnected sources of electric current.

4. A method of arc welding, comprising preheating an electrically conductive work piece by means of a first electric arc between a pair of carbon electrodes with a source of alternating current, thereafter forming a second electric arc in the atmosphere of the first arc between the work piece and a metallic welding rod with a source of direct current, and cooperatively moving said arcs relative to said work piece to accomplish welding of the work piece by fusion therewith of metal from said metallic rod.

5. A method of arc welding work pieces of thin sheet metals and alloys, comprising preheating the work piece by means of a first electric are between a pair of carbon electrodes with a source of alternating current, thereafter forming a second electric arc in the atmosphere of said first arc between the work piece and a metallic welding rod with a source of dir ct current, forming a third electric are between at least one of said carbon electrodes and the work piece, with one of the current sources employed for said first two arcs as a source of current for said third arc, forming a fourth electric are between at least one of said carbon electrodes and said metallic electrode with one of the current sources employed for said first two arcs, and cooperatively moving said arcs relative to said work piece to accomplish welding of the work piece by fusion therewith of metal from said metallic rod.

6, The method of welding metallic work, which consists in preheating the work by means of an electric are between a pair of alternating current electrodes placed in proximity to the work to maintain an effective atmosphere, thereafter introducing a metallic welding rod into said atmosphere of the alternating are, and then forming a welding are by means of direct current through the welding rod and the work and maintaining both arcs, whereby the direct current welding arc may continue to operate in the atmosphere maintained by the alternating current electrodes,

7. The method of welding metallic work with sources of alternating current and direct current, which consists of applying heat to the work and maintaining an efiective atmosphere by means of an electric arc in proximity to the work between a pair of alternating current electrodes, of welding with a metallic electrode in said at mosphere by means of a direct current welding are between the metallic electrode and the work, the direct current welding are being supported by the atmosphere maintained by the alternating current are, and of maintaining direct current potential between said alternating current electrodes and the work.

8. The method of welding metallic work with sources of alternating current and direct current, which consists of supplying heat to the work and maintaining an effective atmosphere by means of an electric arc in proximity to the work between a pair of alternating current electrodes, of welding with a metallic electrode in said atmosphere by means of a direct current welding are between the metallic electrode and the work, the direct current welding are being supported by the atmosphere maintained by the alternating current are, and of maintaining direct current potential between said alternating current electrodes and the work, and between said alternating current electrodes and said metallic electrode.

COLBY WESTON STEWARD. MALCOLM R, RIVENBURGH.

REFERENCES CITED The following references are oi? record in the file of this patent:

UNITED STATES PATENTS Number Name Date 401,639 Cofi'in Apr. 16, 1889 1,542,753 Wiltsie June 16, 1925 1,707,036 Zack Mar. 26, 1929 2,068,691 Murphy Jan, 26, 1937 2,320,824 Landis et al. June 1, 1943 2,340,093 White Jan. 25, 1944 FOREIGN PATENTS Number Country Date 20,769 Great Britain 1905 

